Industrial visit to Diesel Shed

Industrial Visit Report Diesel Loco Shed -Shakurbasti

Submitted by :: Mayank Sharma (631/MP/06)

Industrial visit to Diesel Shed

ACKNOWLEDGEMENT We are grateful to Mr.Pradeep Khanna for making this visit to Diesel Shed possible and for accompanying us on this visit and also solving our various queries. We are also thankful to the professionals the Shakurbasti Diesel Shed for helping us know and understand the various locomotives their principles and operations.

Industrial visit to Diesel Shed

Index
Details About Diesel Shed .4 Diesel Locomotives....5 The Classification Syntaxes7 WDM 2 locomotive.9 WDS 4 locomotive..12 Starting the WDM 2 locomotive ...13 Diesel Hydraulic Transmission.15 Torque Converter15 Diesel Electric Transmission .16 Throttle Converter...16 Main Alternator.18 Motor Blower.18 Compressed Air System..19 Batteries.19 Lubrication.20 Dynamic Brakes.21 Air Brakes23 Testing at Diesel Shed24

Industrial visit to Diesel Shed

Details About the Diesel Shed

It is the pioneer WDS4 Loco shed of Northern Railway and came into existence on 5th April, 1955. From its humble beginning in 1955, the Diesel Shed has evolved to become the premier shed for diesel-hydraulic locomotives over Indian Railways. Showing its commitment towards quality and environmental management, the Diesel Shed has acquired ISO 9001: 2000 and ISO 4001:1996 certifications. This shed has also been entrusted with the maintenance of 140T Gottwald Cranes (Break-down Cranes). This shed is also earning by rendering engineering services to public sector undertakings having 37 locos since 1979 and carrying out all major schedules upto periodic overhauling with total satisfaction of customers.

Total Shed Area Total Covered Area Total Staff

Employed

= 41141 SQM. =15417 SQM. = 800 approx.

Total Capacity for WDS 4 = 108

Industrial visit to Diesel Shed

Diesel locomotives ::
A locomotive is a railway vehicle that provides the motive power for a train. The word originates from the Latin loco - "from a place", Latin motivus, "causing motion". A Diesel locomotive is a type of railroad locomotive in which the prime mover is a Diesel engine.

Diesel locomotives are classified on the basis of the track Gauge over which they are designed to run. 1) 2) 3) Broad Gauge Meter gauge Narrow gauge

All the diesel locomotive repaired and looked after in ShakurBasti diesel shed are of Broad gauge type.

These broad gauge locos can also be classified on the basis of purpose of use. 1) 2) 3) 4) Passenger Locos Goods Locos Mixed type Locos Shunting Locos or switching locos.

Industrial visit to Diesel Shed

Passenger Locos : These are ones which are used to carry passenger
from one place to another WDP 1 WDP 2 WDP 3 WDP 4

Goods locos : They are used for carrying goods.

WDG 2 WDG 3B, WDG 3C, WDG 3D and WDG4

Mixed Locos : They carry both Goods and locos.

WDM 1 WDM 2 WDM 2A WDM 2B WDM 3D WDM 4 WDM 6 WDM 7. WDM 3 WDM 3A WDM 3C

Shunting locos : They are used for shunting purposes.

WDS 1 WDS 2 WDS3 WDS4 WDS 4A WDS4B WDS 4C WDS4D WDS 5 WDS 6 WDS 8.

Along with these there are also Diesel Multiple units :

DHMU

DEMU and

Of All these ShakurBasti loco plant takes care of only : 1) 2) 3) 4) WDM 2 WDS 4 BG DEMU (Broad gauge DEMU) MG DEMU (Meter gauge DEMU)

Industrial visit to Diesel Shed

The classification syntaxes

Locos have classification codes that identify them. This code is of the form [gauge] [power] [load] [series]

In this the first item, '[gauge]', is a single letter identifying the gauge the loco runs on:

W = Broad Gauge Y = Meter Gauge Z = Narrow Gauge (2' 6") N = Narrow Gauge (2')

The second item, '[power]', is one or two letters identifying the power source:

D = Diesel C = DC traction A = AC traction CA = Dual-power AC/DC traction B = Battery electric(rare)

Industrial visit to Diesel Shed

The third item, '[load]', is a single letter identifying the kind of load the loco is normally used for:

M = Mixed Traffic P = Passenger G = Goods S = Shunting L = Light Duty (Light Passenger) U = Multiple Unit (EMU / DEMU)

The fourth item, '[series]', is a digit identifying the model of the loco. Until recently, this series number was simply assigned chronologically as new models of locos were introduced.

With this WDM2 corresponds to :

W = Broad Gauge D = Diesel M = Mixed Traffic 2 = This is a series no.

On the similar basis we can identify different diesel engines.

Industrial visit to Diesel Shed

WDM 2 Locomotive
The WDM-2 is the most common diesel locomotive of Indian Railways. The class WDM-2 is Indian Railways' workhorse diesel locomotive. The first units were imported fully built from the American Locomotive Company (Alco) in 1962. Since 1964, it has been manufactured in India by the Diesel Locomotive Works (DLW), Varanasi. This is the first Homemade Diesel-electric Locomotive (DEL). WDM2 is designed for mixed traffic service, passenger and freight. The loco equipped with fully equalized trimount trucks has medium axle loading and higher adhesion. WDM2 has characteristics of low and easy maintenance, reduced noise and exhaust emissions, fuel saving, safe and comfortable riding and reliable high performance.

Technical specifications : Builders Engine Alco, DLW It has an Alco 251-B, 16 cylinders engine. With Power Output of 2,600 hp

Industrial visit to Diesel Shed It is equipped with Alco 710/720 Turbo supercharger. 1,000 rpm max, 400 rpm idle; 228 mm x 266 mm bore/stroke compression ratio 12.5:1. Direct fuel injection, centrifugal pump cooling system. Governor This engine uses a Hydraulic Governor GE 17MG8 / Woodwards 8574-650 Electric, with BHEL TG 10931 AZ generator (1,000 rpm, 770 V, 4,520 amps). 18.8 tonnes 112.8 t. Alco design cast frame trimount (Co-Co) bogies

Transmission

Axle load Total weight Bogies

Max. Speed Gear ratio

120km/hr 65 : 18

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Industrial visit to Diesel Shed

At the repair track in front of WDM2

Inside the drivers Cab in WDM 2

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Industrial visit to Diesel Shed

WDS 4 Locomotive

These are basically used for shunting purposes i.e. track shifting from on track to another. These are the only IR locos in use today with hydraulic transmission. Technical specifications : Engine : These use 6 cylinder MAK engine. With power output of 700 HP. It uses an electric governor.

Governor:

Transmission : Mak-Suri 2-speed hydromechanical transmission (WDS-4). Total weight : Max Speed : 60 tonnes. 80km/hr

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Industrial visit to Diesel Shed

Starting the WDM 2 Locomotive :

During the visit, with kind co-operation from the Loco shed staff, students were explained the details about how to start the locomotive. These can be summarized as :: The WDM-2 has no key to start the engine - it has a green color switch in the electrical panel to crank the prime mover. Similarly there is a red switch to stop the prime mover. The starting sequence is something like this: 1. First a walk-around of the loco is done ensuring that the loco appears in condition fit for duty. This takes around 10 minutes. All the fluid levels (coolant, lube oil) are checked at this stage. After being started, the loco is checked once again before leaving the shed. 2. Close the battery master switch inside the short hood compartment. 3. Close the fuel pump breaker and wait for the fuel oil pressure gauge to start showing some reading. The presence of fuel oil pressure means that the fuel is present at the injectors when the engine is cranked. 4. Close the crankcase exhauster breaker - this blower removes explosive vapours from the crankcase during operation. 5. Ensure: loco brakes on, generator field breaker open, reverser in the neutral position, Engine Control Switch in the Idle position, throttle in the closed position.

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Industrial visit to Diesel Shed 6. Press the green start switch - the bell will sound inside the engine compartment warning anyone working there that the beast will wake up soon. I think it takes a second push of the button during which the engine is cranked. 7. The switch is to be held down till all the cylinders start firing. 8. Once the prime mover is running, observe the oil pressure, air pressure, brake pipe pressure being build up. 9. Observe the battery charging taking place. The battery charging ammeter in the electrical panel always shows a (center) zero reading - this indicates the charging and discharging of the battery is perfectly balanced. The charging is checked by operating a toggle switch near the ammeter - this toggle switches off the field to the auxiliary generator (meant for battery charging, etc.) and the ammeter immediately shows a small negative deflection indicating a loss of battery charging. Once the switch is closed, the ammeter swings back to the center zero position. 10. Another check of the loco - some drivers open the crankcase exhauster breaker at this stage - the positive pressure inside the crank sometimes shows up oil leaks faster. 11. The throttle is moved to ensure that loco is responding to being notched. 12. Release the parking brake, remove any wedges, wheel blocks, or rocks placed at the wheels to stop the loco from rolling. 13. Move the Engine Control Switch from Idle to Run position. 14. Observe the signal being pulled off, release the loco brakes and honk before moving!

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Industrial visit to Diesel Shed

Diesel hydraulic Transmission ::

WDM 2 loco makes use of Diesel hydraulic transmission to convey power from diesel engines to wheels. On this type of loco, the power is transmitted to the wheels by a device called Torque Converter. Torque converter consists of :: 1) Centrifugal Pump It is the inner rotating part which is mechanically driven by prime mover. As it spins, fluid is flung to the outside , a vacuum is created that draws more fluid in at the center. 2) Turbine Wheel It is the driven wheel,it is on the outer part of the coupling. 3) Stator It is interposed between the pump and turbine so that it can alter oil flow returning from the turbine to the pump As the diesel engine rotates the centrifugal pump, oil is forced outwards at high pressure. The oil is forced through the blades of the fixed guide wheel and then through the blades of the turbine wheel, which causes it to rotate and thus turn the axle and the wheels. The oil is then pumped around the circuit repeatedly. The disposition of the guide vanes allows the torque converter to act as a gearbox with continuously variable ratio. If the output shaft is loaded to reduce its rotational speed, the torque applied to the shaft increases,

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Industrial visit to Diesel Shed so the power transmitted by the torque converter remains more or less constant.

Diesel Electric Transmission ::

In DEL engine prime mover drives an electric generator whose output provides power to the traction motors. Important components of the Diesel electric propulsion are : Prime Mover Main Generator Traction Motors Control System

In principle, the electrical output from the generator is directed through the switchgear to the traction motors, which are mechanically coupled to the drivers by spur gearing.

Throttle Control :
Locomotive power output, and speed, is typically controlled by the engineer (driver) using a stepped or "notched" throttle that produces binary-like electrical signals corresponding to throttle position. This basic design lends itself well to multiple unit (MU) operation by producing discrete conditions that assure that all units in a consist respond in the same way to throttle position. The throttle mechanism is ratcheted so that it is not possible to advance more than one power position at a time. The engineer could
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Industrial visit to Diesel Shed not, for example, pull the throttle from notch 2 to notch 4 without stopping at notch 3. This feature was intended to prevent rough train handling due to abrupt power increases caused by rapid throttle motion .

When the throttle is in the idle position, the prime mover will be receiving minimal fuel, causing it to idle at low RPM. Also, the traction motors will not be connected to the main generator (MG) and the generator's field windings will not be excited (energized) the generator will not produce electricity with no excitation. Therefore, the locomotive will be in "neutral To set the locomotive in motion, the reverser handle is placed into the correct position (forward or reverse), the brakes are released and the throttle is moved to the run 1 position (the first power notch) Placing the throttle into the first power position will cause the traction motors to be connected to the MG and the latter's field coils to be excited. It will not, however, increase prime mover RPM. With excitation applied, the MG will deliver electricity to the traction motors, resulting in motion. If the locomotive is running "light" (that is, not coupled to a train) and is not on an ascending grade it will easily accelerate. On the other hand, if a long train is being started, the locomotive may stall as soon as some of the slack has been taken up, as the drag imposed by the train will exceed the tractive force being developed. As the throttle is moved to higher power notches, the fuel rate to the prime mover will increase, resulting in a corresponding increase in RPM and horsepower output. At the same time, MG field excitation will be proportionally increased to absorb the higher horsepower. This will
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Industrial visit to Diesel Shed translate into increased electrical output to the traction motors, with a corresponding increase in tractive force. Eventually, depending on the requirements of the train's schedule, the engineer (driver) will have moved the throttle to the position of maximum power and will maintain it there until the train has accelerated to the desired speed.

Main Alternator The diesel engine drives the main alternator which provides the power to move the train. The alternator generates AC electricity which is used to provide power for the traction motors mounted on the bogies. In older locomotives, the alternator was a DC machine, called a generator. It produced direct current which was used to provide power for DC traction motors. Many of these machines are still in regular use. The next development was the replacement of the generator by the alternator but still using DC traction motors. The AC output is rectified to give the DC required for the motors.

Motor Blower The diesel engine also drives a motor blower. As its name suggests, the motor blower provides air which is blown over the traction motors to keep them cool during periods of heavy work. The blower is mounted inside the locomotive body but the motors are on the trucks, so the blower output is connected to each of the motors through flexible ducting. The blower output also cools the alternators. Some designs have separate blowers for the group of motors on each truck and

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Industrial visit to Diesel Shed others for the alternators. Whatever the arrangement, a modern locomotive has a complex air management system which monitors the temperature of the various rotating machines in the locomotive and adjusts the flow of air accordingly.

Compressed Air System

Each Diesel engine drives a direct-connected, two-stage, air compressor which takes air from the atmosphere and delivers it under pressure to the main reservoir, where the air is stored and cooled and in which the moisture contained in the air is condensed into water from where it can be readily drained before it enters the various operating parts of the air system. Air from the main reservoirs is piped to the air brake system, the air control system, and to the other air-operated devices used throughout the locomotive.The main reservoir air is connected between units by flexible hose.

Batteries The diesel engine needs a battery to start it and to provide electrical power for lights and controls when the engine is switched off and the alternator is not running. Battery powered vehicles have benefits that include low noise, small vibrations,simplified transmission systems, and reduced pollution when compared to combustion engines.The battery is charged from the auxiliary generator or generators on the unit, and the charging voltage is controlled by a voltage regulator to maintain a

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Industrial visit to Diesel Shed constant voltage of approximately 74 volts.The battery is used for lights in the operating cab and engine room and provides power to the control and indication circuits of the locomotive.

Lubrication Like an automobile engine, a diesel engine needs lubrication. In an arrangement similar to the engine cooling system, lubricating oil is distributed around the engine to the cylinders, crankshaft and other moving parts. There is a reservoir of oil, usually carried in the sump, which has to be kept topped up, and a pump to keep the oil circulating evenly around the engine. The oil gets heated by its passage around the engine and has to be kept cool, so it is passed through a radiator during its journey. The radiator is sometimes designed as a heat exchanger, where the oil passes through pipes encased in a water tank which is connected to the engine cooling system. The oil has to be filtered to remove impurities and it has to be monitored for low pressure. If oil pressure falls to a level which could cause the engine to seize up, a "low oil pressure switch" will shut down the engine. There is also a high pressure relief valve, to drain off excess oil back to the sump.

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Industrial visit to Diesel Shed

Dynamic Braking :
Dynamic braking takes advantage of the fact that the traction motor armatures are always rotating when the locomotive is in motion and that a motor can be made to act as a generator by separately exciting the field winding. When dynamic braking is utilized, the traction control circuits are configured as follows:

The field winding of each traction motor is connected across the main generator (MG). The armature of each traction motor is connected across a forcedair cooled resistance grid (the dynamic braking grid) in the roof of the locomotive's hood. The prime mover RPM is increased and the MG field is excited, causing a corresponding excitation of the traction motor fields.

The aggregate effect of the above is to cause each traction motor to generate electric power and dissipate it as heat in the dynamic braking grid. Forced air-cooling is provided by a fan that is connected across the grid. Consequently, the fan is powered by the output of the traction motors and will tend to run faster and produce more airflow as more energy is applied to the grid.

Ultimately, the source of the energy dissipated in the dynamic braking grid is the motion of the locomotive as imparted to the traction motor armatures. Therefore, the traction motors impose drag and the locomotive acts as a brake.

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Industrial visit to Diesel Shed

Air Brakes :
An air brake is a conveyance braking system applied by means of compressed air. In the air brake's simplest form, called the straight air system, compressed air pushes on a piston in a cylinder. The piston is connected through mechanical linkage to brake shoes that can rub on the train wheels, using the resulting friction to slow the train. The mechanical linkage can become quite elaborate, as it evenly distributes force from one pressurized air cylinder to 8 or 12 wheels. The pressurized air comes from an air compressor in the locomotive and is sent from car to car by a train line made up of pipes beneath each car and hoses between cars.

Modern air brake systems are in effect two braking systems combined: The service brake system, which applies and releases the brakes during normal operations, and The emergency brake system, which applies the brakes rapidly in the event of a brake pipe failure or an emergency application by the engineer.

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Industrial visit to Diesel Shed

Purpose of Diesel Shed ::

The Shakurbasti diesel shed was constructed for repair and maintenance of diesel locos. They follow a strict plan for maintenance of the locos. Every loco has a specific time after which it has return to the Shed for testing and other repairs. Diesel Shed also include a Workshop in which different components of loco are machined or repaired The basic things they inspect upon are : 1) Fuel Tanks 2) Wheels and Axles 3) Brake System 4) Trucks 5) Wheels and Axles 6) Speed Indicators 7) Different Level Switches 8) Audible Signals 9) Illuminating Devices 10) Basic Engine components 11) Turbocharger 12) Radiators 13) Filters 14) Batteries 15) Cab etc.

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Industrial visit to Diesel Shed Basically 4 Non destructive tests are employed in the Diesel Shed.

1) In ultrasonic testing, very short ultrasonic pulse-waves with center frequencies ranging from 0.1-15 MHz and occasionally up to 50 MHz are launched into materials to detect internal flaws or to characterize materials. 2) Magnetic flux leakage (MFL) is a magnetic method of nondestructive testing that is used to detect corrosion and pitting in steel structures, most commonly pipelines and storage tanks. The basic principle is that a powerful magnet is used to magnetize the steel. At areas where there is corrosion or missing metal, the magnetic field "leaks" from the steel. 3) Liquid penetrant inspection (LPI), is a widely applied and low-cost inspection method used to locate surface-breaking defects in all non-porous materials (metals, plastics, or ceramics). Penetrant may be applied to all non-ferrous materials, but for inspection of ferrous components magnetic-particle inspection is preferred for its subsurface detection capability. LPI is used to detect casting and forging defects, cracks, and leaks in new products, and fatigue cracks on in-service components. When used with a Red die it is known as Red Die Penetrant Inspection. Red dye penetrants are visible under normal light .

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Industrial visit to Diesel Shed

4) Zyglo Fluorescent Penetrant Test The ZYGLO fluorescent Penetrant process is a nondestructive testing (NDT) method that helps you locate and identify surface defects in order to screen out potential failure-producing defects, correct production problems and increase product uniformity. It is a quick and accurate process for locating surface flaws such as shrinkage cracks, porosity, cold shuts, fatigue cracks, grinding cracks, heat treat cracks, seams, forging laps, forging bursts, through leaks, and lack of bond. Steps involved in Zyglo test are as follows : STEP 1PRE-CLEAN PARTS STEP 2APPLY PENETRANT STEP 3REMOVE PENETRANT STEP 4DRY PARTS STEP 5APPLY DEVELOPER STEP 6INSPECTION

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